Systems and methods for forming laminates with patterned microwave energy interactive material

ABSTRACT

Portions of microwave energy interactive material may be cut and removed during intermediate steps in a lamination processes, so that remaining microwave energy interactive material in a resultant laminate is arranged in a pattern. Regarding the removal of the portions of the microwave energy interactive material, a compound laminate may be delaminated into parts, and one of the parts may be a sacrificial laminate that includes the removed portions of the microwave energy interactive material.

CROSS-REFERENCED TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/565,195, filed Aug. 2, 2012, which claims the benefit of both U.S.Provisional Application No. 61/514,600, filed Aug. 3, 2011, and U.S.Provisional Application No. 61/569,919, filed Dec. 13, 2011. Each ofU.S. patent application Ser. No. 13/565,195, filed Aug. 2, 2012, U.S.Provisional Application No. 61/514,600, filed Aug. 3, 2011, and U.S.Provisional Application No. 61/569,919, filed Dec. 13, 2011, isincorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

This disclosure relates to systems and methods for making laminates thatinclude patterned microwave energy interactive material and may beformed into constructs, such as blanks, cartons, press-formedconstructs, or the like.

BACKGROUND

Microwave ovens provide a convenient means of cooking and reheating fooditems. Many combinations of materials of different character have beenused in microwave packaging to influence the effect of the microwaveenergy on the food product being heated. These microwave packagingmaterials may be microwave transparent, for example, paper, paperboard,or many plastics, or they may be microwave energy interactive, forexample, metal foils or thin metal deposits. Microwave transparentmaterials generally provide, for example, food product support,packaging form, insulation, and/or vapor barrier functions in packaging.Microwave energy interactive material generally provides, for example,enhanced surface heating, microwave shielding, enhanced microwavetransmission, and/or energy distribution functions in packaging.

Microwave packaging often is created and configured of both microwavetransparent and microwave energy interactive materials. For example,MicroRite brand trays, which are available from Graphic PackagingInternational, Inc., comprise aluminum foil laminated to paperboard. Thealuminum foil is typically configured in predetermined shapes thatdefine a pattern, wherein the shapes/pattern may be formed by chemicallyetching away (in a caustic bath) some of the foil and/or chemicaldeactivation of some of the foil. The configuration of the microwaveenergy interactive material determines the performance characteristicsof the microwave energy interactive material.

BRIEF SUMMARY

One aspect of this disclosure is the provision of systems and methodsfor providing a laminate, wherein the laminate may be formed into aconstruct for use in cooking and/or reheating food in a microwave oven,the laminate includes both microwave transparent and microwave energyinteractive materials, and the microwave energy interactive material maybe formed into a pattern without using chemical etching or deactivation.More specifically and in one example, portions of the microwave energyinteractive material may be cut and removed during intermediate steps inthe lamination processes, so that the remaining microwave energyinteractive material in the resultant laminate is arranged in thepattern. That is, the pattern may be formed without using chemicaletching or chemical deactivation. Further regarding the removal of theportions of the microwave energy interactive material, a compoundlaminate may be separated (e.g., delaminated) into parts, and one of theparts may be a sacrificial laminate that includes the removed portionsof the microwave energy interactive material.

Alternatively, this disclosure is not limited to forming the pattern inthe microwave energy interactive material solely by cutting and removingpredetermined pieces of the microwave energy interactive material. Forexample and optionally, the cutting and removing of the predeterminedpieces of the microwave energy interactive material may be used to forman initial (e.g., coarse) pattern in the microwave energy interactivematerial, and the initial pattern may be fine tuned or otherwisetransformed into a subsequent (e.g., fine) pattern using any suitabletechnique, such as chemical deactivation and/or chemical etching.

In accordance with one aspect of this disclosure, a laminate may havemicrowave interactive material positioned between a barrier layer and asubstrate, the barrier layer may obstruct holes in the microwaveinteractive material, and holes in the substrate may be superposed withthe holes in the microwave interactive material.

The foregoing presents a simplified summary of some aspects of thisdisclosure in order to provide a basic understanding. The foregoingsummary is not an extensive summary and is not intended to identify keyor critical elements of the invention or to delineate the scope of theinvention. The purpose of the foregoing summary is to present someconcepts of this disclosure in a simplified form as a prelude to themore detailed description that is presented below. For example, otheraspects will become apparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described some aspects of this disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale. The drawings are schematic and exemplaryonly, and should not be construed as limiting the invention.

FIG. 1 is a side elevation view of a system for making a resultantlaminate that includes patterned microwave energy interactive material,in accordance with a first embodiment of this disclosure.

FIG. 2 is a side elevation view of a section of an initial laminate,wherein the initial laminate is a precursor to the resultant laminate,and the initial laminate is formed at an upstream laminating station ofthe system, in accordance with the first embodiment.

FIG. 3 is a side elevation view of a section of a kisscut laminate,wherein the kisscut laminate is a precursor to the resultant laminate,and the kisscut laminate is formed at a cutting station of the system,in accordance with the first embodiment.

FIG. 4 is a side elevation view of a compound laminate being separatedor delaminated (e.g., divided) into an intermediate laminate and asacrificial laminate at a separating, stripping or delaminating stationof the system, and each of the compound and intermediate laminates is aprecursor to the resultant laminate, in accordance with the firstembodiment.

FIG. 5 is similar to FIG. 4, except for showing that adhesive segmentsand associated retained microwave energy interactive segments may beslightly out of phase.

FIG. 6 is a representative, isolated top plan view of a combination ofan adhesive segment and a retained microwave energy interactive segmentof FIG. 5, showing that the adhesive segment and retained microwaveenergy interactive segment may be slightly out of phase.

FIG. 7 is like FIG. 5, except for showing that adhesive segments andassociated retained microwave energy interactive segments may beslightly different sizes and/or slightly out of phase.

FIG. 8 is a representative, isolated top plan view of a combination ofan adhesive segment and a retained microwave energy interactive segmentof FIG. 7, showing that the adhesive segment and retained microwaveenergy interactive segment may be slightly different sizes and/orslightly out of phase.

FIG. 9 is a side elevation view of a system for making a resultantlaminate that includes patterned microwave energy interactive material,in accordance with a second embodiment of this disclosure.

FIG. 10 illustrates a section of a resultant laminate that includesretained microwave energy interactive segments, in accordance with anembodiment of this disclosure.

FIG. 11 is a cross-sectional view of a portion of the laminate of FIG.10 taken along line 11-11 of FIG. 10, in accordance with an embodimentof this disclosure.

DETAILED DESCRIPTION

Exemplary embodiments of this disclosure are described below andillustrated in the accompanying figures, in which like numerals refer tolike parts throughout the several views. The embodiments describedprovide examples and should not be interpreted as limiting the scope ofthe invention. Other embodiments, and modifications and improvements ofthe described embodiments, will occur to those skilled in the art andall such other embodiments, modifications and improvements are withinthe scope of the invention.

Referring now in greater detail to the drawings, initially FIG. 1, asystem 20 and associated methods of a first embodiment of thisdisclosure are described in the following. In accordance with one aspectof this disclosure, the system 20 and associated methods may be utilizedin the fabrication of a resultant laminate 22 comprising both microwavetransparent and microwave energy interactive materials. In the resultantlaminate 22, the microwave energy interactive material may be configuredin predetermined shapes that define a pattern, so that theshapes/pattern affect the operativeness of the microwave energyinteractive material. In the system 20 of the first embodiment, thereare several stages respectively associated with laminates that areprecursors to the resultant laminate 22. The precursor laminates may bean initial laminate 24, kisscut laminate 26, compound laminate 28, andintermediate laminate 30.

The initial laminate 24 comprises a web of base material 32 and a webcomprising microwave energy interactive material 34 that are securedtogether. For ease of readability, the web of base material 32 may bereferred to as a base web 32 in the following. Similarly, the webcomprising microwave energy interactive material 34 may be referred toas an interactive web 34 in the following.

The base web 32 is typically suitable for being formed into constructssuch as, but not limited to, blanks, cartons, trays, bowls, press-formedconstructs, or the like, that may include microwave energy interactivematerial. As a more specific example, the base web 32 may be suitablefor being cut into blanks that are for being formed into the constructsthat may include microwave energy interactive material and may be usedin cooking and/or reheating food in a microwave oven. In accordance withthe first embodiment, the base web 32 is paperboard, or alternativelycardboard, although any other suitable material may be used.

In one example, the interactive web 34 may be a web of foil, wherein thefoil is a thin sheet of metal such as, but not limited to, aluminum. Asa more general example, the interactive web 34 may be a web of foilhaving a thickness sufficient to reflect at least a portion (and up to100%) of impinging microwave energy. Such webs of foil typically areforming from a conductive, reflective metal or metal alloy, for example,aluminum, copper, or stainless steel, generally having a thickness offrom about 0.000285 inches to about 0.005 inches, for example, fromabout 0.0003 inches to about 0.003 inches. Such webs of foil may morespecifically have a thickness of from about 0.00035 inches to about0.002 inches, for example, 0.0016 inches.

In another example, the interactive web 34 may comprise a web of foil(e.g., the web of foil discussed above) joined to a substrate, forexample, paper or paperboard (i.e., a foil laminate). The foil may bejoined to the substrate in any suitable manner, for example, using asubstantially continuous layer or any other suitable arrangement ofadhesive material. Such a foil laminate may have greater dimensionalstability and, therefore, may be easier to process (e.g., unwind, kisscut, etc.). The foil that is or is part of the interactive web 34 may bereferred to as layer of microwave interactive material. The microwaveinteractive material may be for influence the effect of the microwaveenergy on a food product being heated in association with a constructformed from a section of the resultant laminate 22. Such a construct maybe formed in a conventional or other suitable manner.

The initial laminate 24 is formed at an upstream laminating station ofthe system 20. The base and interactive webs 32, 34 are respectivelydrawn from supply rolls 36, 38, such as in response to operation of oneor more pairs of nip rollers 40, 42, so that the base and interactivewebs 32, 34 are nipped together between the upstream nip rollers 40.When the interactive web 34 comprises a foil laminate, the foil laminate34 may be configured so that the substrate faces towards the base web 32or away from the base web 32 (e.g., so that the foil is positionedbetween substrate and the base web 32). For example, it may be desirablein some microwave heating products to conceal, partially conceal or maskthe typically silver color of the foil. In other applications, it may bedesirable to provide a particular appearance on the visible side of theresulting laminate. In such applications, the foil laminate 34 may beconfigured so that the foil faces the base web 32 and the substrate(e.g. paper) faces outwardly. The substrate may be white, black, orotherwise colored, patterned, and/or provided with text and/or graphics,as desired, using any suitable technique. Alternatively, it may bedesirable in some microwave heating products to have the foil bevisible, or it may be easier to adhere the substrate to the base web 32in some processes. In such instances, the foil laminate 34 may beconfigured so that the substrate (e.g. paper) faces the base web 32 andthe foil faces outwardly.

Prior to the nipping between the upstream nip rollers 40, one or moreadhesive applicators 46 may apply adhesive material to what will becomethe inner face of the base web 32 and/or what will become the inner faceof the interactive web 34. The one or more adhesive applicators 46 applythe adhesive material in a manner so that there is a predeterminedpattern of adhesive material between the base and interactive webs 32,34 in the initial, kisscut and compound laminates 24, 26, 28. Inaccordance with the first embodiment, the adhesive pattern between thebase and interactive webs 32, 34 may correspond or substantiallycorrespond in shape to the pattern of the microwave energy interactivematerial in the resulting laminate 22, or any other suitable adhesivepattern may be used, as discussed in greater detail below.

Any suitable adhesive material may be supplied by the one or moreadhesive applicators 46. For example, the one or more adhesiveapplicators 46 may supply wet-bond adhesive material, in which case theadhesive material will be tacky during the nipping between the upstreamnip rollers 40. Optionally, any suitable drying system 48, such as adrying oven, may be positioned downstream from the upstream nip rollers40 for at least aiding in the drying of the adhesive material of theinitial laminate 24. The adhesive material supplied from the adhesiveapplicator(s) 46 is dried and/or cured so that the base and interactivewebs 32, 34 are bonded together. Throughout this disclosure, each of theadhesive materials that are discussed may be applied with any suitableadhesive applicators, such as, but not limited to, patterned roll-onapplicators; patterned stamp applicators; movable, computer-controllednozzle applicators, or the like. Also, each of the adhesive materialsmay be dried or otherwise cured in any suitable manner.

In the initial laminate 24, the adhesive pattern between the base andinteractive webs 32, 34 defines both bonded and unbonded areas. Morespecifically and referring to FIG. 2, the segments of the adhesivematerial (“adhesive segments 50”) of the adhesive pattern between thebase and interactive webs 32, 34 define bonded areas of the initiallaminate 24. Accordingly, in each of the bonded areas, the adjacentsurfaces of the base and interactive webs 32, 34 are bonded together bya respective adhesive segment 50. Throughout the drawings, the adhesivesegments 50 are schematically at least partially illustrated byhatching. The adhesive segments 50 indirectly define the unbonded areasof the initial laminate 24 so that, in each of the unbonded areas, theadjacent surfaces of the base and interactive webs 32, 34 are inopposing face-to-face relation (e.g., opposing face-to-face contact)with one another, but are not bonded to one another. Accordingly, in theinitial laminate 24, there are both: sections of the interactive web 34that are bonded to the base web 32, and sections of the interactive web34 that are not bonded to the base web 32. The sections of theinteractive web 34 that are bonded to the base web 32 may be generallyreferred to as bonded interactive sections. More specifically and forreasons that will become more apparent in the following, the sections ofthe interactive web 34 that are bonded to the base web 32 may be morespecifically referred to as retained interactive sections 52. Also forreasons that will become more apparent in the following, the sections ofthe interactive web 34 that are not bonded to the base web 32 may bereferred to as unretained interactive sections and/or scrap interactivesections 54.

Referring back to FIG. 1, the initial laminate 24 is transformed intothe kisscut laminate 26 at a station for forming lines of disruption inthe interactive web 34, and more specifically the station for formingthe lines of disruption may be a cutting station of the system 20. Evenmore specifically, the initial laminate 24 may be transformed into thekisscut laminate 26 through the action of any suitable cutting system56, 58. For example and not for purposes of limitation, the cuttingsystem 56, 58 is shown in FIG. 1 in the form of counter roller 56 and arotary cutter 58, and the initial laminate 24 is drawn between thecounter roller 56 and rotary cutter 58. For example, the rotary cutter58 may be in the form of a roller with outwardly projecting cuttingfeatures, such as cutting rules, cutting blades, or any other suitablecutting edges, configured for forming kiss cuts in the initial laminate24, wherein the kiss cuts are arranged in a pattern (“kisscut pattern”).The kiss cutting occurs on the side of the initial laminate 24 that isdefined by the interactive web 34, and the kiss cuts typically extendcompletely through the interactive web 34 without substantiallypenetrating (e.g., without penetrating, or typically only slightlypenetrating) the base web 32. (It is noted that where the interactiveweb 34 comprises a foil laminate, the kiss cuts typically extend throughboth the foil and the substrate (e.g., paper or paperboard)).Accordingly and referring to FIG. 3, the kiss cuts may be characterizedas being die cuts 60 in the interactive web 34, such that the kisscutpattern is defined by the die cuts 60. Each of the die cuts 60 may bemore generally referred to as a line of separation such as, but notlimited to, a slit, cut line, tear line, line of perforations, and/orthe like. The kisscut pattern/die cuts 60 in the interactive web 34 maybe formed in any suitable manner, such as with one or more rotary dies,flat dies, lasers, and/or the like, such that substantially only theinteractive web 34 is cut.

Referring to FIG. 3, the lines of disruption/kisscut pattern/die cuts 60in the interactive web 34 at least partially define the retained andscrap interactive sections 52, 54 of the interactive web 34. Morespecifically, the lines of disruption/kisscut pattern/die cuts 60respectively substantially separate the retained and scrap interactivesections 52, 54 of the interactive web 34 from one another. Even morespecifically, the kisscut pattern/die cuts 60 are such that each of theretained interactive sections 52 is substantially circumscribed by therespective die cut (e.g., line of separation such as, but not limitedto, a slit, cut line, tear line, line of perforations, and/or the like).As will be discussed in greater detail below, the kisscut pattern andthe adhesive pattern between the base and interactive webs 32, 34 maynot be perfectly matched (e.g., may be slightly offset and/or comprisedifferent sizes).

Referring to FIG. 1, a compound laminate 28 is faulted at anintermediate laminating station of the system 20. The compound laminate28 comprises the kisscut laminate 26 and a web of sacrificial material62 that are secured together. For ease of readability, the web ofsacrificial material 32 may be referred to as a sacrificial web 62 inthe following. For example, the sacrificial web 62 may be a web oflow-cost, disposable material, such as, but not limited to, a thin gaugepolymer film, for example, a polyethylene film, or any other suitablematerial, such as a reused or recycled material, as discussed in greaterdetail below.

The sacrificial web 62 is drawn from a supply roll 64, such as inresponse to operation of one or more pairs of nip rollers 66, 68, sothat the kisscut laminate 26 and sacrificial web 62 are nipped togetherbetween the intermediate nip rollers 68. Prior to the nipping betweenthe intermediate nip rollers 68, one or more adhesive applicators 70apply adhesive material to what will become an inner face of the kisscutlaminate 26 and/or what will become the inner face of the sacrificialweb 62. The adhesive applicator(s) 70 apply the adhesive material in apredetermined pattern so that the scrap interactive sections 54 willbecome bonded to the sacrificial web 62, and the retained interactivesections 52 do not, or more generally substantially do not, becomebonded to the sacrificial web 62. More specifically and in accordancewith one version of the first embodiment, the adhesive material issupplied from the one or more adhesive applicators 70 to the outersurfaces of the scrap interactive sections 54 rather than to theretained interactive sections 52. Alternatively, the adhesive materialmay be supplied from the one or more adhesive applicators 70 to whatwill become the inner face of the sacrificial web 62 so that the scrapinteractive sections 54 will become bonded to the sacrificial web 62,and the retained interactive sections 52 do not, or more generallysubstantially do not, become bonded to the sacrificial web 62.

Any suitable adhesive material may be supplied by the one or moreadhesive applicators 70. For example, the one or more adhesiveapplicators 70 may supply a dry-bond adhesive material. As anotherexample, the one or more adhesive applicators 70 may supply wet-bondadhesive material, in which case the adhesive material will typically betacky during the nipping between the intermediate nip rollers 68.Optionally, any suitable drying system 72, such as a drying oven, may bepositioned downstream from the intermediate nip rollers 68 for at leastaiding in the drying of the adhesive material between the kisscutlaminate 26 and the sacrificial web 62. The adhesive material suppliedfrom the adhesive applicator(s) 70 is dried and/or cured so that thekisscut laminate 26 and sacrificial web 62 are bonded together. As onespecific example, the adhesive material between the kisscut laminate 26and the sacrificial web 62 may be curable by ultraviolet light, thesacrificial web 62 may be transparent and/or translucent, and the dryingsystem 72 may shine ultraviolet light onto the outer surface of thesacrificial web 62 for curing the adhesive material between the kisscutlaminate 26 and the sacrificial web 62.

In the compound laminate 28, the adhesive pattern between the kisscutlaminate 26 and the sacrificial web 62 defines both bonded and unbondedareas in the compound laminate 28. More specifically and referring tothe upstream portion of FIG. 4, the segments of adhesive material(“adhesive segments 74”) of the adhesive pattern between the kisscutlaminate 26 and the sacrificial web 62 are configured so that: the scrapinteractive sections 54 of the kisscut laminate 26 are bonded to thesacrificial web 62, and the retained interactive sections 52 of thekisscut laminate 26 are not bonded (e.g., substantially not bonded) tothe sacrificial web 62. Throughout the drawings, the adhesive segments50, 74 are schematically at least partially illustrated by hatching.

Referring to FIG. 1, the intermediate laminate 30 is formed at astripping, separating or delamination station of the system 20. Theintermediate laminate 30 is formed from the compound laminate 28 byseparating or delaminating the sacrificial web 62 and the scrapinteractive sections 54 from a remainder of the compound laminate 28.More specifically, after the scrap interactive sections 54 have becomesecured to the sacrificial web 62, a sacrificial laminate 76, whichcomprises scrap interactive sections 54 secured to the sacrificial web62, is stripped or delaminated from a remainder of the compound laminate28. For example, the sacrificial laminate 76 may be stripped by drawingthe sacrificial laminate around one or more rollers 78, 80, and formingthe sacrificial laminate into a roll 82. The roll 82 may becharacterized as being schematically illustrative of a conventionalwinding apparatus for forming the sacrificial laminate 76 into a roll.Whereas the sacrificial web 62 and scrap interactive sections 54 areremoved, the retained interactive sections 52 remain secured to the baseweb 32, so that the intermediate laminate 30 comprises the base web 32with retained interactive sections 52 secured thereto. That is, thecompound laminate 28 is separated or delaminated (e.g., divided) intothe intermediate laminate 30 and the sacrificial laminate 76 at theseparating or delaminating station of the system 20.

In accordance with the first embodiment, prior to the intermediatelaminate 30 and the sacrificial laminate 76 being separated ordelaminated from one another, they may be releasably connected to oneanother by way of at least a portion of the die cuts 60 being in theform of breachable lines of disruption such as, but not limited to,line-like arrangements of spaced apart perforations, or other suitabletear lines. Alternatively and/or in addition, and as mentioned above,the kisscut pattern and the adhesive pattern between the base andinteractive webs 32, 34 may not be perfectly matched (e.g., may beslightly offset and/or comprise different sizes) in a manner thatprovides a releasable connection or bond between the intermediatelaminate 30 and the sacrificial laminate 76, as discussed in thefollowing with reference to FIGS. 5-8.

In accordance with the first embodiment and referring to FIGS. 5-8, theone or more adhesive applicators 46 and cutting station/cutting system56, 58 may operate in a coordinated manner so that the adhesive segments50 and retained interactive sections 52 are slightly out of phase and/orthe adhesive segments 50 are slightly larger than the retainedinteractive sections 52. More specifically, the dimension D in FIGS. 5and 6 is illustrative of the adhesive segments 50 and retainedinteractive sections 52 being slightly out of phase. As another example,the dimensions D1 and D2 in FIGS. 7 and 8 are different, and therebyillustrative of the adhesive segments 50 being slightly larger than theretained interactive sections 52, and the adhesive segments 50 andretained interactive sections 52 being slightly out of phase.Alternatively, the adhesive segments 50 may be slightly larger than theretained interactive sections 52 without (e.g., substantially without)the adhesive segments 50 and retained interactive sections 52 being outof phase.

When adhesive segments 50 are slightly larger than the retainedinteractive sections 52 and/or the adhesive segments 50 and retainedinteractive sections 52 are slightly out of phase, a relatively smallmarginal portion of each adhesive segment 50 is adhered or bonded to the(respective) adjacent scrap interactive section(s) 54, as shown in FIGS.5 and 7. The adhesive bond between the relatively small marginal portionof each adhesive segment 50 and the (respective) adjacent scrapinteractive section(s) 54 may perform a desirable function. For example,the adhesive bond between the relatively small marginal portion of eachadhesive segment 50 and the (respective) adjacent scrap interactivesection(s) 54 may advantageously seek to: restrict the scrap interactivesections 52 from being transferred to the cutting tool (e.g., rotarycutter 58), restrict the scrap interactive sections 52 from prematurelyseparating from the base web 32, and/or restrict the intermediate andsacrificial laminates 30, 76 from separating from one anotherprematurely. The adhesive bond between the relatively small marginalportion of each adhesive segment 50 and the (respective) adjacent scrapinteractive section(s) 54 is broken (e.g., via adhesive failure of thebonds/segments 50 and/or cohesive failure of the bonds/segments 50) whenthe compound laminate 28 is separated or delaminated (e.g., divided)into the intermediate laminate 30 and the sacrificial laminate 76 at theseparating or stripping station of the system 20. That is, the adhesivebonds between the relatively small marginal portions of the adhesivesegments 50 and the adjacent scrap interactive sections 54 are smallerthan and/or weaker than the adhesive bonds between the adhesive segments74 and the scrap interactive sections 54 so that the scrap interactivesections 54 are carried away by the sacrificial web 62 as it is strippedaway at the stripping or delaminating station.

Alternatively, a relatively small and/or weaker adhesive bond betweeneach of the scrap interactive sections 54 and the base web 32 may beprovided in any other suitable manner, such that, and similarly todiscussed above, the scrap interactive sections 54 are carried away bythe sacrificial web 62 as it is stripped away at the stripping ordelaminating station. For example, the one or more adhesive applicators46 (FIG. 1) may apply a uniform or substantially uniform pattern of dotsof adhesive material, or any other suitable pattern of adhesivematerial, across an entire surface of the inner face of the base web 32and/or the inner face of the interactive web 34, so that each of thescrap interactive sections 54 is bonded by one or more dots of adhesivematerial to the base web 32. The adhesive bonds between the base web 32and the adjacent scrap interactive sections 54 are smaller than and/orweaker than the adhesive bonds between the sacrificial web 62 and scrapinteractive sections 54 so that the scrap interactive sections 54 arecarried away by the sacrificial web 62 as it is stripped away at thestripping or delaminating station. In accordance with the firstembodiment of this disclosure, the adhesive applicator(s) 46 of theupstream laminating station and/or the rotary cutter 58 of the cuttingstation may be configured so that both the retained interactive sections52 and the scrap interactive sections 54 are bonded to the base web 32.Nonetheless, the connections (e.g., adhesive bonds) within the compoundlaminate 28 may contrast in a predetermined manner for facilitating thedelamination between the intermediate and sacrificial laminates 30, 76.

Referring to FIG. 1, the resultant laminate 22 is formed at a downstreamlaminating station of the system 20. The resultant laminate 22 comprisesthe intermediate laminate 30 and a web of covering material 84 that aresecured together. For ease of readability, the web of covering material84 may be referred to as a barrier web 84 in the following. For example,the barrier web 84 may be a barrier layer of material such as polymerfilm, or more specifically a polyethylene terephthalate film, or anyother suitable material. As should be apparent, the resultant laminate22 includes retained interactive sections 52 arranged in series.

The barrier web 84 is drawn from a supply roll 86, such as in responseto operation of one or more pairs of nip rollers 88, 90, so that theintermediate laminate 30 and barrier web 84 are nipped together betweenthe downstream nip rollers 90. Prior to the nipping between thedownstream nip rollers 90, one or more adhesive applicators 92 applyadhesive material to what will become an inner face of the intermediatelaminate 30 and/or what will become the inner face of the cover web 84,so that the cover web will become broadly, securely adhered or bonded tothe intermediate laminate to form the resultant laminate 22. Anysuitable adhesive material may be supplied by the one or more adhesiveapplicators 92. The adhesive material supplied from the adhesiveapplicator(s) 92 is dried and/or cured so that the intermediate laminate30 and barrier web 84 are bonded together. The resultant laminate 22 maybe formed into a roll 94, and thereafter drawn from the roll and formedinto constructs. The roll 94 may be characterized as being schematicallyillustrative of a conventional winding apparatus for forming theresultant laminate 22 into a roll. The forming of the resultant laminate22 into constructs may be performed in any suitable manner. For example,the resultant laminate 22 may be formed into constructs such as, but notlimited to, blanks, cartons, trays, bowls, press-formed constructs, orthe like.

As mentioned above, the sacrificial laminate 76 may be wound into a roll82, and that roll may be referred to as a sacrificial roll 82. As oneexample, the sacrificial roll 82 may be discarded. As a contrastingexample and for the sake of efficiency, the sacrificial roll 82 mayoptionally be “reused” at least once, such as by moving it (or thesacrificial laminate 76 from it) upstream in the system 20, from thestripping station to the intermediate laminating station, so that thesacrificial roll 82 is used in place of/as the supply roll 64. Stateddifferently, the sacrificial laminate 76 (e.g., the sacrificial laminate76 left over from a prior production run of the system 20) may be usedas the sacrificial web 62 (e.g., in the present production run of thesystem), in which case the sacrificial web 62 may be referred to as arecycled sacrificial laminate. Typically, the recycled sacrificiallaminate (e.g., the sacrificial laminate 76) will be supplied to theintermediate nip rollers 68 so that the preexisting scrap segments ofthe recycled sacrificial laminate (e.g., see the scrap segments 54 ofthe sacrificial laminate 76) will become exterior features of theresulting compound laminate (not shown in detail, but see the compoundlaminate 28 for example). Accordingly, when the recycled sacrificiallaminate is used in a production run as discussed above, the adhesivematerial supplied by the adhesive applicator(s) 70 may be an adhesivematerial other than an adhesive material curable by ultraviolet light,since the exterior, preexisting scrap segments of the resulting compoundlaminate may interfere with transmission of ultraviolet light from thedrying system 72 to the adhesive material positioned between the kisscutlaminate 26 and the recycled sacrificial laminate of the resultingcompound laminate.

A second embodiment of this disclosure is like the first embodiment ofthis disclosure, except for variations noted and variations that will beapparent to one of ordinary skill in the art. In this regard, FIG. 9 isa side elevation view in accordance with the second embodiment, and FIG.9 is similar to FIG. 1, except that some of the features have beenrearranged accordingly. Other arrangements are also within the scope ofthis disclosure.

Referring to FIG. 9, initial and kisscut laminates of the secondembodiment comprise the interactive web 34, sacrificial web 62, andadhesive segments 74 (also see FIGS. 5 and 7, for example), wherein theinitial laminate is formed at the upstream laminating station and thekisscut laminate is formed at the cutting station. Further referring toFIG. 9, the base web 32/adhesive segments 50 (also see FIGS. 5 and 7,for example) are laminated (at the intermediate laminating station) tothe kisscut laminate of the second embodiment to form the compoundlaminate of the second embodiment. That is, the interactive web may bekiss cut/die cut after the interactive web is laminated to thesacrificial web 62 (e.g., as in the second embodiment), or theinteractive web 34 may be kiss cut/die cut after the interactive web islaminated to the base web 32 (e.g., as in the first embodiment). Thecompound laminate of the second embodiment may be like (e.g., identicalto or substantially identical to) the compound laminate 28 of the firstembodiment shown in FIG. 4. Accordingly, the compound laminate 28 of thesecond embodiment is delaminated at the delaminating station into theintermediate and sacrificial laminates 30, 76 of the second embodiment,and thereafter the resultant laminate 22 of the second embodiment isformed at the downstream laminating station.

With regard to the variations of the first embodiment shown in FIGS.5-8, the compound laminate of the second embodiment may be the same asthe compound laminate 28 of the first embodiment, except that in someversions of the second embodiment the adhesive segments 74 and scrapinteractive sections 54 may be slightly out of phase and/or the adhesivesegments 74 may be slightly larger than the scrap interactive sections54 (rather than the adhesive segments 50 and retained interactivesections 52 optionally being slightly out of phase and/or the adhesivesegments 50 optionally being slightly larger than the retainedinteractive sections 52 as in the first embodiment). The adhesivesegments 74 and scrap interactive sections 54 being slightly out ofphase and/or the adhesive segments 74 being slightly larger than thescrap interactive sections 54 may provide advantages generallycorresponding to those discussed above for the first embodiment.

When adhesive bonds are present between the base web 32 and the adjacentscrap interactive sections 54, the adhesive bonds between the base web32 and the adjacent scrap interactive sections 54 are typically smallerthan and/or weaker than the adhesive bonds between the sacrificial web62 and the scrap interactive sections 54, so that the scrap interactivesections 54 are carried away by the sacrificial web 62 as it is strippedaway at the stripping or delaminating station. For example, adhesivebonds between the base web 32 and the adjacent scrap interactivesections 54 may be provided in any suitable manner such as, but notlimited to, by adhesive material arranged in a pattern of dots, asdiscussed above.

A third embodiment of this disclosure is like the first embodiment ofthis disclosure, except for variations noted and variations that will beapparent to one of ordinary skill in the art. The overall system of thethird embodiment may be understood by referring to the system 20 of thefirst embodiment. As may be understood with reference to FIG. 1, in thethird embodiment the positions of the base and barrier webs 32, 84 areinterchanged as compared to the first embodiment. Accordingly, thebarrier web 84 (rather than the base web 32) is supplied from theupstream supply roll 36, so that the covering and interactive webs 84,34 are nipped together between the upstream nip rollers 40.Correspondingly, the base web 32 (rather than the barrier web 84) issupplied from the downstream supply roll 86, so that the base web 32 andthe intermediate laminate 30 are nipped together between the downstreamnip rollers 90 to form a resultant laminate. As a result ofinterchanging the base and barrier webs 32, 84 as discussed above, theresultant laminate of the third embodiment would be like the resultantlaminate 22 of the first and second embodiments, except for beinginverted. Notwithstanding the foregoing, this disclosure is not limitedto the orientations and/or relative positions shown in the drawingsand/or discussed above. As one example, the entire system 20 shown inFIG. 1 may be inverted. Likewise, other orientations, relative positionsand/or the like are within the scope of this disclosure.

A fourth embodiment of this disclosure is like the first, second andthird embodiments of this disclosure, except for variations noted andvariations that will be apparent to one of ordinary skill in the art.Due to the similarity, components of the fourth embodiment that areidentical, similar and/or function in at least some ways similarly tocorresponding components of the first, second and third embodiments havereference numbers incremented by one hundred or two hundred.

Referring to FIG. 10, the retained interactive sections 152, 252, whichare in the resultant laminate 122 of the fourth embodiment, define aseries of microwave energy interactive assemblies that extends along thelength of the resultant laminate, wherein each of the microwave energyinteractive assemblies includes first and second retained interactivesections 152, 252. Only a single, representative microwave energyinteractive web, assembly or apparatus is shown in FIG. 10. Theinteractive sections 152 and/or the interactive sections 252 may beomitted and/or configured differently than shown in FIG. 10.

As shown in FIG. 10, the first retained interactive section 152 is inthe form of a metal foil band including somewhat rounded corners 104 andobround holes 106 in a spaced apart configuration. As used in thisDetailed Description section of this disclosure for the fourthembodiment, the term “obround” refers to a shape substantiallyconsisting of two semicircles connected by parallel lines tangent totheir endpoints. The second retained interactive section 252 is the formof metal foil segments 110 arranged in clusters in a lattice-likeconfiguration. Only a few of the foil segments 110 are identified bytheir reference numeral in FIG. 10. The first retained interactivesection 152 is spaced from and forms a border around the second retainedinteractive section 252.

FIG. 11 is a schematic cross-sectional view of the resultant laminate122 taken along line 11-11 in FIG. 10, wherein only the cross section isshown in FIG. 11. In the embodiment shown in FIGS. 10 and 11, and asbest understood with reference to FIG. 11, the barrier web 184 spanscontinuously across the entire resultant laminate 122, so that thebarrier web 184 obstructs each of the holes (e.g., the holes 106) in theretained interactive sections 152, 252, or more specifically the barrierweb 184 spans across each of the holes in the retained interactivesections 152, 252, or even more specifically the barrier web 184completely covers each of the holes in the retained interactive sections152, 252. Similarly, the base web 132 completely covers each of theholes (e.g., the holes 106) in the retained interactive sections 152,252, such that each of the holes may optionally or theoretically be inthe form of a completely closed cavity.

Partially reiterating from above and mainly referring to FIG. 11, theinteractive web 34 (see, e.g., FIG. 1) may optionally be a foil laminatecomprising a layer or web of foil 195 joined to a web, layer orsubstrate 196 (e.g., paper or paperboard) by a layer of adhesivematerial 197, so that each of the retained interactive sections 152, 252includes the foil 195, substrate 196 and adhesive material 197. As shownin FIG. 11, the resultant laminate 122 farther includes the base web 132that is connected to the foil 195 by the adhesive segments 150, and thebarrier web 184 that is connected to the substrate 196 by a layer ofadhesive material 198 supplied from the one or more adhesive applicators92 (see, e.g., FIG. 1). The barrier web 184 and the adhesive material198 may be transparent (e.g., substantially transparent), and thesubstrate 196 may be opaque, so that the substrate 196 is operative forconcealing, partially concealing or masking the typically silver colorof the foil 195 and/or functioning in any other suitable manner, such asdiscussed above.

In the embodiment shown in FIGS. 10 and 11, the cutter 58 (e.g., seeFIG. 1) and/or other features of the cutting system are configured sothat lines of disruption or die cuts 60 (FIGS. 3-5) are formed anddefined in each of the foil 195 (FIG. 11), substrate 196 (FIG. 11) andadhesive material 197 (FIG. 11); the lines of disruption or die cuts 60define pattern(s) in the foil 195, the lines of disruption or die cuts60 define pattern(s) in the substrate 196, and the lines of disruptionor die cuts 60 define a pattern(s) in the adhesive material 197; thepattern(s) in the foil 195, the pattern(s) in the substrate 196, and thepattern(s) in the adhesive material 197 are superposed with respect toone another; each of the holes 106 includes a hole in the foil 195, ahole in the substrate 196, and a hole in the adhesive material 197; andfor each of the holes 106, the hole in the foil 195, hole in thesubstrate 196, and hole in the adhesive material 197 are superposed withrespect to one another.

FIG. 11 may be schematic because, for example, the thickness of theretained interactive section 152 may be exaggerated and, in contrast towhat is shown in FIG. 11 and with reference to the orientation shown inFIG. 11, the adhesive material 198 may extend into the holes (e.g., theholes 106) in the retained interactive sections 152, 252 and be directlybonded to the portions of the base web 132 that partially define theholes. Therefore, the barrier web 184 may extend into the holes (e.g.,the holes 106) in the retained interactive sections 152, 252, and thebarrier web 184 may be bonded (by way of the adhesive material 198) tothe portions of the base web 132 that partially define the holes.

Alternatively, the interactive web 34/retained interactive sections 152,252 may be inverted relative to the other layers of the resultantlaminate 122, the substrate 196 and adhesive material 197 may beomitted, other layers or webs may be omitted, and/or other layers orwebs may be included in the resultant laminates. The above-disclosedpatterns (e.g., of the retained interactive sections 52, 152, 252) areprovided as examples only, and other patterns are within the scope ofthis disclosure. For example, one or more of the above-discussedpatterns (e.g., of the retained interactive sections 52, 152, 252) maybe tailored to the desired end uses of the resultant laminates 22, 122.

The above-described exemplary embodiments are in no way intended tolimit the scope of the present invention. It will be understood by thoseskilled in the art that while the present disclosure has been discussedabove with reference to exemplary embodiments, various additions,modifications and changes can be made thereto without departing from thespirit and scope of the invention as set forth in the claims.

What is claimed is:
 1. A method of forming a laminate comprising apattern of microwave interactive material, the method comprising:forming an initial laminate comprising a base web and an interactiveweb, the interactive web comprising a microwave interactive material,the forming the initial laminate comprising bonding the base web to theinteractive web with adhesive material that is arranged in a pattern ofadhesive segments to form a plurality of bonded areas and a plurality ofunbonded areas of the interactive web; forming a plurality of cuts in atleast the interactive web, the plurality of cuts at least partiallydefining a plurality of retained sections and a plurality of scrapsections in the interactive web, each retained section of the pluralityof retained sections comprising at least a portion of a respectivebonded area of the plurality of bonded areas, and each scrap section ofthe plurality of scrap sections comprising at least a portion of arespective unbonded area of the plurality of unbonded areas; forming acompound laminate comprising the initial laminate and a sacrificial web,the forming the compound laminate comprising bonding the sacrificial webto at least a portion of the plurality of scrap sections of theinteractive web; and separating the compound laminate into a firstlaminate and a second laminate comprising moving the sacrificial web andthe base web relative to one another, the first laminate comprising atleast the base web and at least a portion of the plurality of retainedsections of the interactive web, and the second laminate comprising atleast the sacrificial web and at least a portion of the plurality ofscrap sections of the interactive web.
 2. The method of claim 1, whereinthe plurality of retained sections of the interactive web are moresecurely bonded to the base web than the plurality of scrap sections ofthe interactive web are bonded to the base web.
 3. The method of claim2, wherein the plurality of scrap sections of the interactive web aremore securely bonded to the sacrificial web than the plurality ofretained portions of the interactive web are bonded to the sacrificialweb.
 4. The method of claim 1, wherein adjacent adhesive segments of theplurality of adhesive segments are spaced apart from one another.
 5. Themethod of claim 4, wherein adjacent adhesive segments of the pluralityof adhesive segments are spaced apart by respective regions that aredevoid of adhesive material.
 6. A method of forming a laminatecomprising a pattern of microwave interactive material, the methodcomprising: forming an initial laminate comprising a base web and aninteractive web, the interactive web comprising a microwave interactivematerial, the forming the initial laminate comprising bonding the baseweb to the interactive web to form a plurality of bonded areas and aplurality of unbonded areas of the interactive web; forming a pluralityof cuts in at least the interactive web, the plurality of cuts at leastpartially defining a plurality of retained sections and a plurality ofscrap sections in the interactive web, each retained section of theplurality of retained sections comprising at least a portion of arespective bonded area of the plurality of bonded areas, and each scrapsection of the plurality of scrap sections comprising at least a portionof a respective unbonded area of the plurality of unbonded areas,wherein at least one of the retained sections of the plurality ofretained sections comprises a first portion of at least one bonded areaof the plurality of bonded areas of the interactive web, at least one ofthe scrap sections of the plurality of scrap sections comprises a secondportion of the at least one bonded area, and the first portion of the atleast one bonded area is larger than the second portion of the at leastone bonded area; forming a compound laminate comprising the initiallaminate and a sacrificial web, the forming the compound laminatecomprising bonding the sacrificial web to at least a portion of theplurality of scrap sections of the interactive web; and separating thecompound laminate into a first laminate and a second laminate comprisingmoving the sacrificial web and the base web relative to one another, thefirst laminate comprising at least the base web and at least a portionof the plurality of retained sections of the interactive web, and thesecond laminate comprising at least the sacrificial web and at least aportion of the plurality of scrap sections of the interactive web.
 7. Amethod of forming a laminate comprising a pattern of microwaveinteractive material, the method comprising: forming an initial laminatecomprising a base web and an interactive web, the interactive webcomprising a microwave interactive material, the forming the initiallaminate comprising bonding the base web to the interactive web to forma plurality of bonded areas and a plurality of unbonded areas of theinteractive web; forming a plurality of cuts in at least the interactiveweb, the plurality of cuts at least partially defining a plurality ofretained sections and a plurality of scrap sections in the interactiveweb, each retained section of the plurality of retained sectionscomprising at least a portion of a respective bonded area of theplurality of bonded areas, and each scrap section of the plurality ofscrap sections comprising at least a portion of a respective unbondedarea of the plurality of unbonded areas, wherein each scrap section ofthe plurality of scrap sections comprises a portion of at least onebonded area of the plurality of bonded areas; forming a compoundlaminate comprising the initial laminate and a sacrificial web, theforming the compound laminate comprising bonding the sacrificial web toat least a portion of the plurality of scrap sections of the interactiveweb; and separating the compound laminate into a first laminate and asecond laminate comprising moving the sacrificial web and the base webrelative to one another, the first laminate comprising at least the baseweb and at least a portion of the plurality of retained sections of theinteractive web, and the second laminate comprising at least thesacrificial web and at least a portion of the plurality of scrapsections of the interactive web.
 8. The method of claim 7, wherein eachretained section of the plurality of retained sections comprises aportion of at least one unbonded area of the plurality of unbondedareas.
 9. The method of claim 7, wherein the separating the compoundlaminate into the first laminate and the second laminate causes adhesivebond failure between the plurality of scrap sections and the base web.10. A method of forming a laminate comprising a pattern of microwaveinteractive material, the method comprising: forming an initial laminatecomprising a base web and an interactive web, the interactive webcomprising a microwave interactive material, the forming the initiallaminate comprising bonding the base web to the interactive web to forma plurality of bonded areas and a plurality of unbonded areas of theinteractive web; forming a plurality of cuts in at least the interactiveweb, the plurality of cuts at least partially defining a plurality ofretained sections and a plurality of scrap sections in the interactiveweb, each retained section of the plurality of retained sectionscomprising at least a portion of a respective bonded area of theplurality of bonded areas, and each scrap section of the plurality ofscrap sections comprising at least a portion of a respective unbondedarea of the plurality of unbonded areas, wherein the bonded areas of theplurality of bonded areas are larger than the respective retainedsections of the plurality of retained sections so that at least onescrap section of the plurality of scrap sections comprises a marginalportion of at least one bonded area of the plurality of bonded areas;forming a compound laminate comprising the initial laminate and asacrificial web, the forming the compound laminate comprising bondingthe sacrificial web to at least a portion of the plurality of scrapsections of the interactive web; and separating the compound laminateinto a first laminate and a second laminate comprising moving thesacrificial web and the base web relative to one another, the firstlaminate comprising at least the base web and at least a portion of theplurality of retained sections of the interactive web, and the secondlaminate comprising at least the sacrificial web and at least a portionof the plurality of scrap sections of the interactive web.
 11. Themethod of claim 10, wherein each of the retained sections of theplurality of retained sections comprises a main portion of therespective bonded area of the plurality of bonded areas, and themarginal portion of the at least one bonded area of the plurality ofbonded areas is relatively smaller than the main portion of therespective bonded area.
 12. A method of forming a laminate comprising apattern of microwave interactive material, the method comprising:forming an initial laminate comprising a base web and an interactiveweb, the interactive web comprising a microwave interactive material,the forming the initial laminate comprising bonding the base web to theinteractive web to form a plurality of bonded areas and a plurality ofunbonded areas of the interactive web; forming a plurality of cuts in atleast the interactive web, the plurality of cuts at least partiallydefining a plurality of retained sections and a plurality of scrapsections in the interactive web, each retained section of the pluralityof retained sections comprising at least a portion of a respectivebonded area of the plurality of bonded areas, and each scrap section ofthe plurality of scrap sections comprising at least a portion of arespective unbonded area of the plurality of unbonded areas, wherein theplurality of bonded areas are out of phase with the plurality ofretained sections so that each retained section of the plurality ofretained sections comprises a first portion of the respective bondedarea of the plurality of bonded areas, and so that each scrap section ofthe plurality of scrap sections comprises a second portion of at leastone respectively adjacent bonded area of the plurality of bonded areas;forming a compound laminate comprising the initial laminate and asacrificial web, the forming the compound laminate comprising bondingthe sacrificial web to at least a portion of the plurality of scrapsections of the interactive web; and separating the compound laminateinto a first laminate and a second laminate comprising moving thesacrificial web and the base web relative to one another, the firstlaminate comprising at least the base web and at least a portion of theplurality of retained sections of the interactive web, and the secondlaminate comprising at least the sacrificial web and at least a portionof the plurality of scrap sections of the interactive web.
 13. Themethod of claim 12, wherein the second portion of each bonded area ofthe plurality of bonded areas is relatively smaller than the respectivefirst portion of each bonded area of the plurality of bonded areas. 14.A method of forming a laminate comprising a pattern of microwaveinteractive material, the method comprising: forming an initial laminatecomprising a base web and an interactive web, the interactive webcomprising a microwave interactive material, the forming the initiallaminate comprising bonding the base web to the interactive web to forma plurality of bonded areas and a plurality of unbonded areas of theinteractive web, wherein the bonding the base web to the interactive webcomprises applying a plurality of adhesive segments to at least one ofthe base web and the interactive web in an adhesive pattern so that eachadhesive segment of the plurality of adhesive segments defines therespective bonded areas of the plurality of bonded areas of theinteractive web; forming a plurality of cuts in at least the interactiveweb, the plurality of cuts at least partially defining a plurality ofretained sections and a plurality of scrap sections in the interactiveweb, each retained section of the plurality of retained sectionscomprising at least a portion of a respective bonded area of theplurality of bonded areas, and each scrap section of the plurality ofscrap sections comprising at least a portion of a respective unbondedarea of the plurality of unbonded areas; forming a compound laminatecomprising the initial laminate and a sacrificial web, the forming thecompound laminate comprising bonding the sacrificial web to at least aportion of the plurality of scrap sections of the interactive web; andseparating the compound laminate into a first laminate and a secondlaminate comprising moving the sacrificial web and the base web relativeto one another, the first laminate comprising at least the base web andat least a portion of the plurality of retained sections of theinteractive web, and the second laminate comprising at least thesacrificial web and at least a portion of the plurality of scrapsections of the interactive web.
 15. The method of claim 14, wherein theadhesive segments of the plurality of adhesive segments are spaced apartfrom one another to at least partially define the plurality of unbondedareas of the interactive web.
 16. The method of claim 14, wherein theplurality of adhesive segments comprises a plurality of first adhesivesegments, and the bonding the sacrificial web to at least a portion ofthe plurality of scrap sections of the interactive web comprisesapplying a plurality of second adhesive segments to at least one of thesacrificial web and the plurality of scrap sections of the interactiveweb.
 17. The method of claim 14, wherein the forming the plurality ofcuts in at least the interactive web comprises forming each retainedsection of the plurality of retained sections to be smaller than therespective bonded area of the plurality of bonded areas so thatrespectively adjacent scrap sections of the plurality of scrap sectionscomprise a marginal portion of the respective bonded area.
 18. Themethod of claim 17, wherein the separating the compound laminate intothe first laminate and the second laminate causes adhesive bond failurebetween the plurality of scrap sections and the base web.
 19. The methodof claim 14, wherein the forming the plurality of cuts in at least theinteractive web comprises forming the plurality of retained sections tobe out of phase with the plurality of bonded areas so that each scrapsection of the plurality of scrap sections comprises a marginal portionof a respectively adjacent bonded area of the plurality of bonded areas.20. The method of claim 19, wherein the separating the compound laminateinto the first laminate and the second laminate causes adhesive bondfailure between the plurality of scrap sections and the base web.